Apparatus for forming elongated elements



July 15, 1969 R. M. BERGER ETAL. 3,455,766

APPARATUS FOR FORMING ELONGATED ELEMENTS ,06f/Az@ M. feafe 25A ws C. Spena@ Maf/1255,27 K. /aL 95A/ BY Awb] g: OAWJSOM,

ATTORNEYS.

July 15, 1969 R. M. BERGER ETAL 3,455,766

V APPARATUS FOR FORMING ELONGATED ELEMENTS med May 1a, lese 4 sheets-sheet z INVENTORS. ,21u/Ae@ M. Bagage EEA ws 6. Spam/4 /fafzr K. /aLf/v LAQ-C051' @MSM ATTORNEYS.

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APPARATUS FOR FORMING ELONGATED ELEMENTS 4 Sheets-Sheet 5 Filed May 18, 1966 4 Sheets-Sheet 4 R. M. BERGER ETAL.

APPARATUS FOR FOBMING ELONGATED ELEMENTS July 15, 1969 Filed May 18 1966 Nw w m m @u NY United States Patent O 3,455,766 APPARATUS FOR FORMING ELONGATED ELEMENTS Richard M. Berger and Reavis C. Sproull, Richmond, and

Herbert K. Holden, Bon Air, Va., assignors to American Filtrona Corporation, a corporation of New York Filed May 18, 1966, Ser. No. 551,158 Int. Cl. B32b 23/02 U.S. Cl. 156-433 14 Claims This invention relates to apparatus for making elongated elements and relates more particularly to various modifications and improvements in the means for making stable, elongated elements suitable for use in smoke filters and the like as disclosed in copending application Ser. No. 502,250, filed Oct. 22, 1965, now abandoned, and assigned to the same assignee as the instant application.

The apparatus for this invention is particularly useful for the formation of cigarette filters and the like from a substantially continuous lamentary tow such as cellulose acetate, but as explained in more detail in the aforementioned copending application such apparatus is also useful in the production of filter rods or the like formed formed from other iilamentary material. Further, the-apparatus may be used to form elongated elements predominantly of particulate materials such as shown in copending application Ser. No. 351,162, filed Mar. 1l, 1964, now abandoned, and assigned to the same assignee as the instant application. Moreover, although the manufacture of cigarette filters and the like is of primary interest, it is to be understood that the concepts disclosed herein can be equally applied to the production of other elongated elements. However, for convenience, the specific embodiments disclosed will be discussed in terms of the manufacture of smoke filter elements and the like from a continuous lilamentary tow such as cellulose acetate.

In this regard, the copending applications disclose an apparatus wherein an endless, flexible, porous belt is continuously moved through processing machinery, the belt being wrapped around the material to form the same into an elongated element. While the material is so-confined in the belt, steam and then a cooling gas are passed through the belt and itno contact with the material to rst activate a bonding consitiuent in the material and to then rigidify the material into a rod which, after separation from the belt, may be subdivided to form cigarette filfer plugs or the like. Reference may be made to the aforementioned copending applications for more details as to the production techniques and products so formed.

It is a primary object of this invention to provide -an apparatus of the type described which is extremely compact and designed for quick and easy assembly and which is especially adapted for correlation with conventional cigarette filter plug manufacturing apparatus. In this manner, a production line according to this invention can be inexpensively integrated with maufacturing equipment ordinarily available in the plant to avoid large additional capital investments.

Another important objective of this invention is the provision of such an apparatus wherein selected elements or the entire line can be readily disassembed for maintenance or for replacement by conventional plugmaking constructions adapted for production of other types of cigarette filters and the like without requiring extensive down time. Along these same lines, it is a further object of this invention to provide manufacturing apparatus of the type described which includes means for selectively adjusting the position or functional relationship of various parts to permit expeditious arrangement and rearrangement of the individual elements to satisfy particular manufacturing requirements.

ICC

Yet another important object of this invention is the provision of a novel means for varying the circumference of the finished product without requiring disassembly or replacement of any of the elements of the overall apparatus whereby the manufacturer need not maintain an inventory of different size processing elements or even porous belts of different thicknesses to effect the product modification.

A still further object of this invention is to provide a means for readily operatively engaging and disengaging the endless `belt with the processing machinery in the absence of providing for separation of various split or two-piece elements to allow for insertion and removal of the belt Whenever necessary. 'In this regard, the instant invention contemplates the provision of processing elements which include continuous bores through which the endless belt is to pass with a parallel passageway through which the belt may be readily laterally inserted into the bore or removed therefrom and with a means for effectively sealing the passageway when the apparatus is 1n use.

Finally, and in general, it is a basic object of this invention to provide a fully integrated and coordinated production line for making elongated elements which is sturdy and durable in construction, reliable and etlicient in operation and relatively inexpensive to manufacture, assemble, utilize and maintain.

Other and further objects reside in the combination of elements, arrangement of parts and features of construction.

Still other objects will in part be obvious and in part be pointed out as the description of the invention proceeds and as shown in the accompanying drawings wherein:

FIGURE 1 is a side elevational view, partly schematic, of one form of an apparatus in accordance with this invention, shown in use for the production of a stable elongated element from a continuous filamentary tow;

FIGURE 2 is a top plan view of the basic apparatus of the invention as shown in FIGURE 1;

FIGURE 3 is an enlarged fragmentary plan view of a portion of the apparatus of this invention shown in FIG- URE l;

FIGURE 4 is a fragmentary side elevational View of the portion of the apparatus shown in FIGURE 3;

FIGURE 5 is an entrance end elevational view taken substantially on line 5-5 of FIGURE 4;

FIGURE 6 is a transverse cross-sectional view taken substantially on line 6 6 of FIGURE 4;

FIGURE 7 is a transverse cross-sectional view taken substantially on line 7--7 of FIGURE 4;

FIGURE 8 is an enlarged fragmentary plan view of the remainder of the apparatus shown in FIGURE 1;

FIGURE 9 is a side elevational view of the portion of the apparatus shown in FIGURE 8;

FIGURE l0 is a transverse cross-sectional View taken substantially on line 10-10 of FIGURE 9;

FIGURE l1 is a transverse cross-sectional view taken substantially on line 11-11 of FIGURE 9;

FIGURE l2 is an exit end elevational view taken substantially on line 12-12 of FIGURE 9;

FIGURE 13 is a fragmentary horizontal cross-sectional view taken substantially on line 13--13 of FIGURE 9;

FIGURE 14 is a fragmentary horizontal cross-sectional view taken substantially on line 14--14 of FIGURE 9;

FIGURE 15 is an enlarged transverse cross-sectional View through a modified and preferred form of a portion of the apparatus in accordance with this invention showing a cooling block having means for adjusting the circumference of the main bore therethrough;

FIGURE 16 is a fragmentary longitudinal cross-sec- 3 tional view taken substantially on line 16-16 of FIG- URE 15;

FIGURE 17 is a transverse cross-sectional view similar to FIGURE l5, but showing the position of the elements when the main cooling block bore has been enlarged;

FIGURE 18 is a top plan view of the modified cooling block of FIGURE 15; and

FIGURE 19 is a side elevational view of the modied cooling block, partly in section for illustrative clarity.

Like reference characters refer to like parts throughout the several views of the drawings.

Referring now to the drawings in general, and more particularly to FIGURES 1 and 2, one form of an apparatus in accordance with this invention is designated generally by the reference numeral 25. Although, as has been mentioned hereinabove, the apparatus can be utilized for the formation of elongated elements from particulate material or the like, FIGURE l illustrates the formation of such a product 26 from a continuous lamentary tow 28. Details of the formation of the tow 28 and its pretreatment such as banding and plasticizing the same as well as subsequent handling of the product 26 such as subdividing the same to form individual filter plug elements can be found in afore-mentioned copending application Ser. No. 502,250.

An endless, flexible, porous belt 30, details of which may also be found in the earlier copending applications, is driven in a continuous orbit, such as for example, by the drum 32. During such orbital travel, the belt 30 passes over a plurality of idlers 34, 36, 38 and 40, one of which shown at 36 may be adjustably positioned to selectively y vary the tension on the belt 30.

The apparatus 25 includes an initial forming station 42 at the entrance end of the same which receives the belt 30 and the tow 28 and folds the belt around the tow until the longitudinal edge portions of the belt 30 are juxtaposed and the tow 28 is confined therewith. From the initial forming station 42, the belt with the tow inside is moved into a steam treating station 44 wherein steam is passed through the belt into contact with the tow to activate a bonding constituent of the tow such as the plasticizer. Since the longitudinal edge portions of the belt 30 do not generally form a perfect seam, the belt and tow are then passed into a ridge remover station 46 in which any longitudinal seam formed on the tow by imperfect meeting of the edge portions of the belt is eliminated by pressingly engaging such portion of the tow with an element while the belt carries the tow past the same. After such ridge removing operation the belt and tow therewithin are moved through a cooling station 48 wherein air or other such iluid medium is passed through the belt land into contact with the tow to deactivate the bonding constituent, if necessary, and t dry the tow by removing steam condensate therefrom whereby the tow is rigidied to form the continuous, stable, elongated element 26.

Referring now to the remainder of the drawings for various structural details and features of the apparatus of this invention, it will be seen that the elements defining the various processing stations discussed hereinabove are carried by a common, elongated supporting member. Specifically, the various elements of the apparatus are carried by a U-shaped member 50 which has a pair of spaced, upstanding legs 52, 54 connected by a bottom 56, the legs and bottom together defining an upwardly opening channel extending substantially the entire length of the apparatus 25 beneath a linear portion of the orbital path of the belt 30. It will be seen that conventional plugmaking machinery can be readily adapted to support the channel member 50 and thereby the entire processing line of this invention in place of selected portions of the conventional equipment which are not capable of producing stable, elongated elements such as contemplated herein. For example, the well-known Molins plug-making machiuery is adapted to manufacture tow-type filter rods which require paper overwrapping to facilitate subsequent processing and handling. The garniture assembly of such equipment can be removed and replaced with a modied garniture support element which will adapt the Molins device to carry and operate the equipment of this invention without in any way affecting the conventional tow preparation processing equipment, the conventional cutter head assembly or the like. It is not considered necessary to illustrate the details of such a modified garniture support since construction of such an element will vary depending on the conventional equipment to be adapted for the processing line of this invention.

In effect, the use of a modified garniture support such as discussed above functions merely to provide a connecting element between the prior art plug making apparatus available to the manufacturer and the processing line of this invention. However, it is to be understood that the apparatus of this invention can be provided with its own machine bed to support and drive the same. In any event, by using a common supporting member such as the channel member 50, in addition to providing inexpensive integration of the apparatus of this invention with equipment ordinarily available to the manufacturer, selected elements or the entire processing line can be readily disassembled for maintenance, adjustment or replacement thus simplifying production techniques and thereby decreasing the overall costs of manufacture.

By referring now particularly to FIGURES 3-5, the details of the initial forming station 42 will be seen. An entrance block 60 seats in the channel of the supporting member 50 and denes an upwardly opening groove 62 which tapers to a reduced cross-sectional area as it approaches the steam treating station 44. A tongue 63- includes an arcuate tongue member 64 which overlies the entrance block 60 and defines a downwardly opening groove 66 complementary to the groove 62 and similarly tapering toward the steam treating station 44. The crosssectional area at any point along the tongue member 64 is slightly less than the cross-sectional area of .a cor responding portion of the groove 62 in the entrance block 60. In this manner, the tongue and groove means functions to fold the belt 30 about the tongue member 64 while the tow 28 is maintained beneath the tongue memberwhereby the tow is confined within the belt as they moveA together into the steam treating station 44.

Ihe tongue 63 is adjustably supported above the entrance block 60 to permit variation in the horizontal and vertical positioning of the tongue groove 66 with respet to the groove 62 of entrance block 60. To provide this adjustability, a tongue support element 67 is secured to one leg 54 of the channel member 50 by screws or the like 68. A tongue bracket 70 includes a vertically extending portion 72 having an elongated arcuate slot 74 through which a screw member 76 is engaged in a tapped aperture 78 in the tongue support element 67. Vertical adjustment of the tongue member 64 is effected by the set screws 80 whch extend through a horizontal portion 82 of the tongue bracket 70 and bear against the top of the tongue support element 67, the screw 76 xing the elements in their vertically adjusted relation. Lateral or horizontal adjustment of the tongue member 64 is effected by the set screws 83 which extend through an oiset portion 84 of the tongue bracket 70 and bear against the edge of an angle member 86 ixed to the top of the tongue member 64 and slidingly received on the horizontal portion 82 of the tongue bracket 70. A screw 87 extends through an elongated slot 88 in the angle member 86 and is secured in a tapped aperture 89 in the horizontal portion 82 of the tongue bracket 70 to iix the tongue member 64 in its laterally adjusted position.

The steam treating station 44 comprises basically a steam block 90 which seats in the channel of the supporting member 50 and which includes portions defining a main longitudinal bore 92 extending from one end ofthe block to the other. The bore 92 is substantially axially aligned in use with the opposing grooves 62, 66 in the forming station 42 and substantially corresponding in diameter to the minimum portion of the entrance block groove 62. Thus, while the belt with the tow therewithin is moved through the steam block bore 92, the tow is finally formed and maintained in a predetermined shape at least substantially corresponding to the conguration of the final product.

Approximately midway along the length of the steam block 90 a steam chamber 94 is defined with a plurality of generally radial apertures 96 connecting the same with the steam block bore 92. The steam chamber 94 may be formed in any desired manner, the drawings showing merely for illustration a chamber 94 which was formed by boring through the steam block 90 from three sides, drilling the apertures 96 through the thus-formed openings, closing the top and bottom openings with plugs such as shown at 98 and then securing a conduit 100 in the remaining opening, the conduit 100 being connected to a source of steam (not shown). Of course, the exact shape of the steam chamber 94 or the manner of forming the same in the steam block 90 can be varied without departing from the instant inventive concept.

According to an important feature of the instant invention, an auxiliary bore 102 is defined in the steam block 90 at least substantially paralleling, and slightly spaced from, the main steam block bore 92. A first longitudinal passageway 104 interconnects the auxiliary bore 102 with the main bore 92 and a second longitudinal passageway 106 interconnects the auxiliary bore 102 with a side surface of the steam block 90. The passageways 104, 106 extend the full length of the respective bores and are dimensioned so that the endless belt 30 may be flattened and passed laterally through the passageways and the auxiliary bore 102 for inserting or removing the same from the main steam block bore 92. In this manner, the belt 30 can be readily operatively engaged with, and disengaged from, the steam block 90 before the manufacturing procedure is begun and after it is completed without the necessity of providing a split steam block as would otherwise be required since the belt is endless.

In order to preclude escape of steam through the passageway 104, a sealing means in the form of a tube 108 formed of Tygon or other suitable material is disposed in the auxiliary bore 102 and expanded by fluid pressure into contact with the walls of the bore. Details of insertion and removal of the tube 108 will be set forth in more detail hereinafter. The end of the tube 108 may be closed by a clamp 110 and fluid pressure is then fed into the opposite end to maintain the sealing relationship during use of the apparatus.

Once again, merely for illustrative purposes, a simplified manufacturing procedure is shown in the drawings wherein one-half of the auxiliary bore 102 is formed in a portion of the steam block 90 with the remainder of the auxiliary bore 102 being formed in a separate cap member 112 secured to the remainder of the steam block by screws or the like 114. After the cap member 112 is secured to the remainder of the steam block, the passageway 106 may be reamed therefrom.

By using the lateral passageways and sealing means described above, after the initial assembly of the steam block, it is not necessary to remove any of the elements other than the tube 108 for insertion and removal of the belt 30. A metal elbow 116 may be fitted around the end of the tube 108 adjacent the steam block 90 and a metal sleeve 117 may be fitted around the portion of the tube 108 in the ridge remover station 46 to preclude undue expansion of these portions of the tube during ination of the same. It is only adjacent the steam block 90 where the environmental temperatures are elevated that such precautions need be taken since the tubing has sufficient integrity at ambient or only slightly elevated temperatures to prevent excessive expansion.

Referring now particularly to FIGURES 8-14, it will be seen that the cooling station 48 comprises a cooling block 120 which seats in the channel defined by the support member 50 and which is illustrated as formed with a cap member 122 secured thereto by screws 124 in a manner similar to the cap 112 of the steam block 90. The cooling block 120 includes a main bore 126 aligned with the main steam block bore 92, an auxiliary bore 128 aligned with the steam block auxiliary bore 102 and passageways 130 and 132 serving a similar function to the passageways 104 and 106 of the steam block. In this manner, the belt 30 can be inserted or removed through the passageways and the auxiliary bores in both the steam block 90 and the cooling block 120 and the tubing 108 can function to simultaneously seal the main bores in both blocks. An additional bore 134 is defined in the `cooling block 120 irnrnediately above the main bore 126, the ends of the additional bore 134 being closed and conduits 136 communieating therewith to provide a source of a cooling gas such as air to the additional bore 134. A plurality of apertures 137 interconnect the additional bore 134 with the main cooling block bore 126 and a plurality of at least substantially diametrically opposed apertures 138 connect the main bore 126 with a channel 140 extending along the bottom of the cooling block 120. A slot 142 is defined in the bottom 56 of the supporting member 50 and a drip pan 144 is positioned beneath the slot 142. It will be understood that if a modified garniture support such as discussed hereinbefore is utilized the drip pan 144 may be secured beneath the same with a slot being defined in the garniture support aligned 'with the slot 142. A conduit 146 is connected to the drip pan 144 for removing moisture therefrom or with conduit 146 closed off a conduit 148 may connect to the drip pan for vacuum withdrawal of the moisture ladened cooling air.

Cooling gas under pressure from the additional bore 134 feeds downwardly through the apertures 137, and then passes through the belt 30 and the tow therewithin and out of the opposite side of the belt through the apertures 138, the channel and the slot 142 into the drip pan 144. In this manner, any condensate remaining in the tow from the steam treating station 44 is removed by entraining the same in the cooling gas whereby the tow is dried and rigidified to form the same into the continuous, stable, elongated product 26.

An exit block 150 is also carried by the channel support 50 and defines a tapered, upwardly opening groove 152 to facilitate separating the belt 30 from the product 26.

Since the longitudinal edge portions of the belt 30 do not generally form a perfect seam, a longitudinal ridge will be present on the tow as it leaves the steam treating station 44. Therefore, a ridge removing station 46 is interposed between the steam treating station 44 and the cooling station 48 to delete this ridge before the tow is rigidified. As will be seen particularly in FIGURES 8-10, the ridge removing station 46 includes a ridge remover 154 carried by a portion of the cooling block 120 at the end adjacent the steam treating station 44. A pair of set screws 156 cooperate with a screw 158 which slides in an elongated slot 160 defined in the ridge remover 154 and seats in a tapped bore 161 defined in an upwardly extending portion of the cooling block 120 to provide for adjustment of the ridge remover 154, the remainder of the cooling block adjacent this end being cut away to permit an element 162 carried by the ridge remover to extend downwardly between the longitudinal edge portions of the belt 30 and pressingly engage any ridge formed on the tow to eliminate the same.

As mentioned previously, to preclude undue expansion of the tube 108 in this open portion of the apparatus, a metal sleeve 117 is positioned thereabout before sliding the remainder of the tube into the auxiliary bores 128 and 102 in the cooling and steam blocks, respectively. This sleeve 117 seats in a groove 164 defined in the cooling block 120 aligned with the auxiliary bores 128 and 102.

A chamber 166 is defined about the cut-away portion of the cooling block 120 by a housing member 168 having end elements 170, 172 resting on the steam block and the cooling block, respectively and side elements 174 enclosing the chamber. A vacuum tube 176 pulls a light vacuum in the chamber 166 to continuously sweep the air from therewithin and withdraw any steam escaping from the main steam block bore 92 at the point where the tow and belt enter the chamber 166.

To insert the tube 108, the metal sleeve 117 is positioned thereabout approximately the length of the steam block 90 from the open end of the tube. This sleeve has an outside diameter slightly smaller than the auxiliary bore 128. The open end of the tube 108 is passed into the auxiliary bore 128 at the exit end of cooling block 120, through this bore, the ridge remover station and on through auxiliary bore 102 with the metal sleeve 117 being positioned between the steam and cooling blocks. At the end of the tube 108, the elbow 116 is placed adjacent the entrance end of the steam block 90. The clamp 110 is then secured closing the open end of the tube 108.

Referring now particularly to FIGURES -19, a modified and preferred form of cooling block is shown which incorporates means for adjusting the circumference of the main bore to provide a small variation in the size of the final product. In these figures, parts similar to the previous embodiment have been designated by the same reference numeral followed by the sufiix a. An elongated groove 180 is formed in the side Wall of the cooling block 120a opposite to the side wall with which the passageway 132a connects the auxiliary bore 12811. This groove is so formed that a relatively thin, flexible portion of the cooling block remains connecting the groove 180 to the main cooling block bore 126:1, this iiexible portion being identified in the drawings as 182. A plurality of pairs of set screws 184, 186 are carried by the upper portion of the cooling block 120g, one set screw of each pair seating on the portion of the cooling block 120a defining the bottom of the groove 180 and the other set screw of each pair being received in tapped apertures 188 defined in this lower surface of the groove 180. By proper adjustment of the set screws 184, 186 the portions defining the upper and lower surfaces of the groove 180 may be moved toward and away from each other thereby pivoting the upper half of the cooling block 120a about the flexible portion 182 to enlarge or reduce the circumference of the main cooling block bore 126a. Comparison of FIGURES l5 and 17 will show an adjustment wherein the cooling block bore 126a has been slightly enlarged to produce a final product of increased crosssection. It will be understood that the adjustment shown in these figures is greatly magnified for illustrative purposes since a cooling block of this type is only intended to produce minor variations of circumference in the product within the limits of the out-of-roundness effected by the bore adjustment which can be accepted in ordinary processing. In any event, slight modifications of the overall dimensions of the final product may be effected in this manner without providing a substitute cooling block with a different diameter bore. Of course, the belt 30 may be replaced by a belt of a slightly different thickness, to effect a similar result, but such a procedure requires maintenance of a belt inventory and substitution of the same in use.

In order that a ridge remover (not shown) similar to the previous embodiment may be utilized with the modified cooling block 120a, the end of the block adjacent to the end of the steam treating station is cut away to provide an open upper portion over a major extent of the width. The groove 180 is then connected with the open upper portion in spaced relationship to the end by a slit 190 extending to the top of the cooling block thereby providing a fixed or stationary portion 192 on which the ridge remover may be mounted. With such a construction, pivotal movement caused by adjustment of the main cooling block bore will in no way affect the positioning of the ridge remover which remains stationary since the portion 192 does not move when adjustment is effected.

Of course, similar adjustment may be provided in the steam block, if desired, but since the tow is not rigidified until passed through the cooling block, such slight variation of the product size may be generally effected in the cooling station alone.

Sealing of the auxiliary bore 12,81 will in no way be affected by the aforementioned adjustment since expansion of the tube 108 will readily maintain the Sarne in sealing contact with the auxiliary bore walls.

Assembly of the various elements in the production line of the instant invention is readily accomplished by merely seating the entrance block, the steam block, the cooling block and the exit block in the channel of the supporting member 50 and aligning the bores by passing a rod or the like through the same. Shims may then be used, as necessary, to secure each of the elements in the channel of the supporting member. The tongue and groove means and the ridge remover means may then be adjustably positioned in their desired location and the endless belt 30 slid through the various passageways and auxiliary bores into operative relationship in the main bores of the steam and cooling blocks. After placing the sleeve 117 about the tube 108, this element is passed through the auxiliary bores of the steam and cooling blocks, the elbow 116 is positioned on the open tubing end, clamp afiixed and tubing expanded therein into sealing engagement. Finally, the housing 168 is positioned over the ridge remover means and the apparatus is ready for operation.

Disassembly may `be readily effected by merely reversing the above procedure and various individual elements may be replaced or removed for maintenance in a simple and efficient manner.

As to the operation of the apparatus of this invention, it will be seen that the belt is folded about the tow by the tongue and groove means functioning in cooperation with the main lbore of the steam block and as the same passes through the steam treating station, the plasticizer or other bonding constituent of the tow is activated by contact with the steam. Any ridge or longitudinal seam formed by the mating edges of the belt is removed by the element 162 and the tow is dried and rigidified in the cooling station 48 to form the continuous, elongated, stable element 26 which may be subsequently subdivided, if desired, to form filter plug elements or otherwise processed depending upon the ultimate use of the same.

It will now be seen that there is herein provided an improved apparatus for forming elongated elements which satisfies all of the objectives of the instant invention, and others, including many advantages of great practical utility and commercial importance.

Since many embodiments may be made of the instant inventive concept, and since many modifications may Ibe made of the embodiments hereinbefore shown and described, it is to `be understood that all matter herein is to be interpreted merely as illustrative and not in a limiting sense. Accordingly, what is claimed is:

1. In an apparatus for making a stable elongated element from a continuous tow wherein a bonding constituent of the tow is activated by steam and wherein the element is subsequently rigidified by a cooling gas, said apparatus including:

(a) an endless, flexible, porous belt;

(b) means for moving the belt through a continuous orbit;

(c) means for feeding the tow onto the belt during a portion of its orbit;

(d) means for forming the belt and the tow into a predetermined shape;

(e) means for passing steam through the belt and into contact with the tow while the belt is moving and while the belt and the tow are maintained in the predetermined shape to thereby activate the bonding constituent;

(f) means for passing cooling gas through the belt and into contact with the tow while the belt is moving and while the belt and the tow are maintained in the predetermined shape to thereby rigidify the tow and form the same into a stable continuous element of the predetermined shape; and

(g) means for separating the stable continuous element from the belt;

the improvement which comprises:

(l) an elongated supporting member extending beneath the belt over a linear portion of its orbital path and having an entrance end and an exit end;

(2) cooperating tongue and groove means carried by said supporting member at said entrance end thereof; said tongue and groove means receiving the belt from the means moving the same and receiving the tow from the means feeding the same, and said tongue and groove means cooperating to form the belt at least substantially into the predetermined shape with the tow therewithin by folding the belt around the tow until the longitudinal edge portions of the belt are juxtaposed;

y(3) a steam block carried by said supporting member in juxtaposition to said tongue and groove means, portions of said steam block defining a longitudinal bore extending at least substantially along the full length of said steam block, and communicating with the exterior of said steam block at Iboth ends of the same, the belt containing the tow moving through said steam block ybore after passing from said tongue and groove means while said steam block bore maintains the belt and tow therewithin in the predetermined shape, and means communicating with said steam block bore intermediate the ends of the same for passing steam through the belt and into contact with the tow therewithin to thereby activate the bonding constituent of the tow;

(4) and a cooling block carried by said supporting member in juxtaposition to said steam block, portions of said cooling block defining a longitudinal bore at least substantially axially aligned with said steam block bore, said cooling block bore extending at least substantially along the full length of said cooling block and communieating with the exterior of said cooling block at both ends of the same, the belt containing the tow moving through said cooling block bore after passing from said steam block while said cooling block bore maintains the belt and tow therewithin in the predetermined shape, and means communicating with said cooling block bore intermediate the ends of the same for passing a cooling gas through the belt and into contact with the tow therewithin to thereby rigidify the tow and form the same into a stable continuous element of the predetermined shape.

2. The improvement defined in claim 1 wherein said supporting member defines an upwardly opening channel extending along its full length, said steam block and said cooling block seating in said channel in supporting relationship.

3. The improvement defined in claim 2 further including a ridge remover supported in said linear portion of the orbital path of the belt intermediate said steam block bore and said cooling block bore, said ridge remover having an element extending between the longitudinal edge portions of the belt after the belt containing the tow leaves said steam block bore and before the belt containing the tow enters said cooling block lbore, said ridge remover element pressingly engaging any ridge formed on the tow by imperfect meeting of the longitudinal edge portions of the belt to remove any such ridge before the tow is rigidified by the cooling gas.

4. The improvement defined in claim 3 further including a ridge remover housing carried by portions of said steam block and portions of said cooling block and overlying said ridge remover to dene a closed chamber thereabout, and vacuum means communicating with said chamber to continuously sweep the air therewithin and remove any steam escaping from said steam block bore as the belt and tow exits therefrom.

5. The improvement defined in claim 2 wherein said tongue and groove means includes an entrance block seating in said channel in supporting relationship and having portions defining a tapered groove decreasing in crosssectional area as it approaches said steam block, and tongue means carried by sid supporting member and having portions defining a complementary tapered groove disposed in facing relationship to said entrance block groove, and means for selectively adjusting the horizontal and vertical relationship of said portions defining said tongue groove with respect to said entrance block groove.

6. The improvement defined in claim 1 wherein said steam block includes means communicating with said steam block 4bore for passing steam through the belt and into the tow therewithin to thereby activate the bonding constituent of the tow whereby the steam will condense in the tow, said cooling block including means communicating with said cooling block bore for passing cooling gas through the belt, into and through the tow therewithin, and then out of the belt at a point substantially diametrically opposed to the point at which it entered the belt, and means communicating with said cooling block bore for withdrawing the cooling gas passing out of the belt and thereby continuously removing steam condensate from the tow by entraining such condensate in the cooling gas.

7. The improvement defined in claim 1 wherein said steam block further includes portions defining an auxiliary longitudinal bore extending at least substantially parallel to, and slightly spaced from, said steam block bore, a first longitudinal passageway connecting said steam block bore with said steam block auxiliary bore over the full length of said steam block bore, and a second longitudinal passageway connecting said steam block auxiliary bore with a side surface of said steam block over the full length of said steam block auxiliary bore, said cooling block including portions defining an auxiliary longitudinal bore at least substantially axially aligned with said steam block auxiliary bore, said cooling block auxiliary bore extending at least substantially parallel to, and slightly spaced from, said cooling block bore, a first longitudinal passageway connecting said cooling block bore with said cooling block auxiliary bore over the full length of said cooling block bore, and a second longitudinal passageway connecting said cooling block auxiliary bore with a side surface of said cooling block over the full length of said cooling block auxiliary bore, and a sealing means extending through said steam block auxiliary bore and said cooling block auxiliary bore in sealing engagement with the respective walls of said auxiliary bores, all of said longitudinal passageways being dimensioned to allow passage of the belt therethrough when the belt is inserted into, and removed from, said steam block bore and said cooling block bore.

8. The improvement defined in claim 7 wherein said sealing means includes a continuous tube extending through said auxiliary bores, means closing one end of said tube, and fluid pressure means communicating with the interior of said tube at its other end for expanding said tube into sealing engagement with the respective walls of said auxiliary bores.

9. The improvement defined in claim 7 wherein said cooling block includes means for selectively varying the circumference of said cooling block bore, said last mentioned means including portions of said cooling block defining a longitudinal groove in the side surface of said cooling 'block opposite to the side surface which said cooling block auxiliary bore is connected to by said second cooling block longitudinal passageway, a flexible, longitudinal portion of said cooling block connecting said longitudinal groove with said cooling block bore, and adjustable means operatively associated with said cooling block to selectively move toward and away from each other the upper and lower portions of said cooling block defining said longitudinal groove whereby the portion of said cooling block above said flexible portion which defines the upper surface of said cooling vblock bore is pivoted about said flexible portion to move away from and toward each other the upper and lower portions of said cooling block defining said second cooling block longitudinal passageway thereby enlarging and reducing the circumference of said cooling block bore.

10. The improvement defined in claim 9 wherein said cooling block includes and end juxtaposed to said steam block, said cooling block having an open upper portion over a major part of its width adjacent said end, portions of said cooling block in spaced relationship to said end defining a slit extending to the top of said cooling block and connecting said longitudinal groove with said open upper portion to provide a fixed portion of said cooling f block remaining at said end beyond said longitudinal groove, a ridge remover carried by said fixed portion of said cooling block, said ridge remover having an element extending between the longitudinal edge portions of the belt after the belt containing the tow leaves said steam block bore and before the belt containing the tow enters said cooling block bore, said ridge remover element pressingly engaging any ridge formed on the tow by imperfect meeting of the longitudinal edge portions of the belt to remove any such ridge before the tow is rigidified by the cooling gas.

11. In an apparatus including at least one element having portions defining a continuous main bore communicating wtih the exterior of the element at opposite ends of the same and an endless belt to be received in the main -bore during use of the apparatus, such use of the apparatus requiring that the circumference of the main bore be sealed against pressure release at other than desired locations over the full length of the main bore, the improvement which comprises portions of said element defining an auxiliary bore extending in slightly spaced relationship with respect to the main bore and communicating with the exterior of the element at opposite ends of the same, a first passageway connecting the main bore with said auxiliary bore over the full length of the main bore, and a second longitudinal passageway connecting said auxiliary bore with a side surface of the element over the full length of said auxiliary bore, and a sealing means extending through said auxiliary bore in sealing engagement with the walls of the same, both of said passageways being dirnensioned to allow passage of the belt therethrough when the belt is inserted into, and removed from, the main bore.

12. The improvement defined in claim 11 including a plurality of successively positioned elements each having axially aligned main bores in which the endless belt is to be received, each of the elements having portions defining axially aligned auxiliary bores and first and second passageways dimensioned for passage of the belt, said sealing means including a continuous tube extending through all of said auxiliary bores.

13. The improvement defined in claim 11 wherein the element includes means for selectively varying the circumference of the main bore, said last-mentioned means including portions of the element defining a groove in the side surface of the element opposite to the side surface which said auxiliary bore is connected to by said second passageway, a flexible, longitudinal portion of the element connecting said groove with the main bore, and adjustable means operatively associated with the element to selectively move toward and away from cach other the upper and lower portions of the element defining said groove whereby the portion of the element above said flexible portion which defines the upper surface of the main bore is pivoted about said flexible portion to move away from and toward each other the upper and lower portions of the element defining said second passageway thereby enlarging and reducing the circumference of the main bore.

14. In an apparatus including at least one element having portions defining a continuous bore communicating with the exterior of the element at opposite ends of the same, the improvement which comprises means for selectively varying the circumference of the main bore, said means including portions of the element defining a passageway connecting the main bore with a side surface of the element over the full length of the main bore, additional portions of the element defining a groove in the side surface of the element opposite to the side surface which the main bore is connected to by said passageway, a fiexible, longitudinal portion of the element connecting said groove with the main bore, and adjustable means operatively associated with the element to selectively move toward and away from each other the upper and lower portions of the element dening said groove whereby the portion of the element above said fiexible portion which defines the upper surface of the main bore is pivoted about said flexible portion to move away from and toward each other the upper and lower portions of the element defining said passageway thereby enlarging and reducing the circumference of the main bore.

References Cited UNITED STATES PATENTS 1/1967 Cobb et al 156-498 XR 4/1968 Berger et al. 264-123 XR U.S. C1. X.R. 15 6-498 

1. IN AN APPARATUS FOR MAKING A STABLE ELONGATED ELEMENT FROM A CONTINUOUS TOW WHEREIN A BONDING CONSTITUENT OF THE TOW IS ACTIVATED BY STEAM AND WHEREIN THE ELEMENT IS SUBSEQUENTLY RIGIDIFIED BY A COOLING GAS, SAID APPARATUS INCULDING; (A) AN ENDLESS, FLEXIBLE, POROUS BELT; (B) MEANS FOR MOVING THE BELT THROUGH A CONTINUOUS ORBIT; (C) MEANS FOR FEEDING THE TOW ONTO THE BELT DURING A PORITON OF ITS ORBIT; (D) MEANS FOR FORMING THE BELT AND THE TOW INTO A PREDETERMINED SHAPE; (E) MENAS FOR PASSING STEAM THROUGH THE BELT AND INTO CONTACT WITH THE TOW WHILE THE BELT IS MOVING AND WHILE THE BELT AND THE TOW ARE MAINTAINED IN THE PREDETERMINED SHAPE TO THEREBY ACTIVATE THE BONDING CONSTITUENT; (F) MEANS FOR PASSING COOLING GAS THROUGH THE BELT AND INTO CONTACT WITH THE TOW WHILE THE BELT IS MOVAND WHILE THE BELT AND THE TOW ARE MAINTAINED IN THE PREDETERMINED SHAPE TO THEREBY RIGIDIFY THE TOW AND FORM THE SAME INTO A STABLE CONTINUOUS ELEMENT OF THE PREDETERMINED SHAPE; AND (G) MEANS FOR SEPARATING THE STALBLE CONTINUOUS ELEMENT FROM THE BLET; THE IMPROVEMENT WHICH COMPRISES: (1) AN ELONGATED SUPPORTING MEMBER EXTENDING BENEATH THE BELT OVER A LINEAR PORTION OF ITS ORBITAL PATH AND HAVING AN ENTRANCE END AND AN EXIT END; (2) COOPERATING TONGUE AND GROOVE MEANS CARRIED BY SAID SUPPORTING MEMBER AT SAID ENTRANCE END THEREOF; SAID TONGUE AND GROOVE MEANS RECEIVING THE BLET FROM THE MEANS MOVING THE SAME AND RECEIVING THE TOW FROM THE MEANS FEEDING THE SAME, AND SID TONGUE AND GROOVE MEANS COOPERATING TO FORMK THE BELT AT LEAST SUBSTANTIALLY INTO THE PREDETERMINED SHAPE WITH THE TOW THEREWITHIN BY FOLDING THE BELT AROUND THE TOW UNTIL THE LONGITUDINAL EDGE PORTIONS OF THE BELT ARE JUXTAPOSED; (3) A STEAM BLOCK CARRIED BY SAID SUPPORTING MEMBER IN JUXTAPOSITION TO SAID TONGUE AND GROOVE MEANS, PORTIONS OF SAID STEAM BLOCK DEFINING A LONGITUDINAL BORE EXTENDING AT LEAST SUBSTANTIALLY ALONG THE FULL LENGTH OF SAID STEAM BLOCK, AND COMMUNICATING WITH THE EXTERIOR OF SAID STEAM BLOCK AT BOTH ENDS OF THE SAME, THE BELT CONTAINING THE TOW MOVING THROUGH SAID STEAM BLOCK BORE AFTER PASSING FROM SAID TONGUE AND GROOVE MEANS WHILE SAID STEAM BLOCK BORE MAINTAINS THE BLET AND TWO THEREWITHIN IN THE PREDETERMINED SHAPE, AND MEANS COMMUNICATING WITH SAID STEAM BLOCK BORE INTERMEDIATE THE ENDS OF THE SAME FOR PASSING STEAM THROUGH THE BELT AND INTO CONTACT WITH THE TOW THEREWITHIN TO THEREBY ACTIVATE THE BONDING CONSTITUENT OF THE TOW; (4) AND A COOLING BLOCK CARRIED BY SAID SUPPORTING MEMBER IN JUXTAPOSITION TO SAID STEAM BLOCK, PROTIONS OF SAID COOLING BOLCK DEFINING A LONGITUDINAL BORE AT LEAST SUBSTANTIALLY AXIALLY ALIGNED WITH SAID STEAM BLOCK BORE, SAID COOLING BLOCK BORE EXTENDING AT LEAST SUBSTANTIALLY ALONG THE FULL LENGTH OF SAID COOLING BLOCK AND COMMUNICATING WITH THE EXTERIOR OF SAID COOLING BLOCK AT BOTH ENDS OF THE SAME, THE BELT CONTAINING THE TOW MOVING THROUGH SAID COOLING BLOCK BORTE AFTER PASSING FROM SAID STEAM BLOCK WHILE SAID COOLING BLOCK BORE MAINTAINS THE BELT AND TOW THEREWITHIN IN THE PREDETERMINED SHAPE, AND MEANS COMMUNICATING WITH SAID COOLING BLOCK BORE INTERMEDIATE THE ENDS OF THE SAME FOR PASSING A COOLING GAS THROUGH THE BELT AND INTO CONTACT WITH THE TOW THEREWITHIN TO THEREBY RIGIDIFY THE TOW AND FORM THE SAME INTO A STABLE CONTINUOUS ELEMENT OF THE PREDETERMINED SHAPE. 